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Instructions and Repair Parts Manual for Ironworker Model Number P2

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Instructions and Repair Parts Manual for Ironworker Model Number P2 INSTRUCTIONS AND REPAIR PARTS MANUAL FOR IRONWORKER MODEL NUMBER P2 Publication: September, 2012 For Serial Numbers Be sure to register your model P2- and serial number to receive to Current Models www.megafab.com Piranha Service and Product 800-338-5471 Updates. Piranha Optional Tooling and Attachments Enhance your Ironworker’s Versatility Oversize Punch Attachments • Expand your punching capacity up to 3" Quickset Gauging Table Allows you to quickly set-up your punch end for multiple holes. Includes an angle gauge bar to index off the heel of your angle and a plate gauge bar, which indexes off the end of your plate. Extensions are available in left and right hand styles in 5' and 10' lengths. Backgauge • Allows you to quickly set-up your machine to repeat your shearing length by adding a mechanical backstop. • Backstop can be positioned in either the angle, flat bar, or round bar section of the machine. • Available in lengths of 3', 6', 9’, or 12'. • An electronic version is also available, which cycles the machine automatically when material makes contact with the backgauge probe. Pipe Notching Attachment • Allows you to single notch Schedule 40 Pipe. • A must have for handrail jobs. • Attaches to the punch end of the machine. • Notching dies available for 3/4", 1", 1-1/4", 1- 1/2", and 2" Schedule 40 Pipe. • Oversize Bending Attachments • Expand your bending capacity to 24" on most models, 12” on the P2 • Includes a 4-way die block for different thicknesses of material. ***Additional Options Shown on Inside of Back Cover*** INSTRUCTIONS AND REPAIR PARTS MANUAL FOR IRONWORKER MODEL NUMBER P2 Publication: September, 2012 P.O. Box 1206 Rockford, IL 61105 PH: 800-338-5471 FAX: 815-964-0831 www.megafab.com TABLE OF CONTENTS Refer to second section of this manual for information on repair parts breakdown and ordering repair parts. Page No. FORWARD ................................................................................................. 4 WARRANTY ............................................................................................... 4 INTRODUCTION ........................................................................................ 5 SAFETY PRECAUTIONS ........................................................................... 6 MACHINE SPECIFICATIONS .................................................................... 7 FUNCTIONAL DIAGRAM ........................................................................... 8 DIMENSIONAL DATA ................................................................................. 9 STANDARDS COMPLIANCE. ................................................................... 10 INSTALLATION ......................................................................................... 11 OPERATING INSTRUCTIONS .................................................................. 12 LUBRICATION ........................................................................................... 20 MAINTENANCE ......................................................................................... 21 TROUBLESHOOTING ............................................................................... 22 PUNCH TONNAGE CHART ...................................................................... 17 TOOL LIST ................................................................................................ 18 PUNCH & DIE CLEARANCE CHART ........................................................ 18 ORDERING INSTRUCTIONS .................................................................... 25 REPAIR PARTS ILLUSTRATIONS .......................................................... RP-1 REPAIR PARTS ILLUSTRATION INDEX ................................................ RP-2 SERVICE RECORD CHART .................................................................. RP-20 FOREWORD This manual has been prepared for those persons who will operate and maintain the Piranha Ironworker. It is important that all persons responsible for the care and operation of this equipment read and understand the information presented in this publication. The illustrations and instructions on the following pages were the most recent available at the time of publication and selection of this material was made based on a standard machine arrangement. Differences between the machine you received and the views contained in this manual are the result of design improvement and / or the addition of optional accessories specified on your order. WARRANTY Mega Manufacturing will replace (F.O.B. our factory), or refund the purchase price for any goods which are defective in materials and workmanship within 12 months of date of purchase. The buyer must return the warranty registration card within thirty- (30) days of the purchase date, and at the seller's option, return the defective materials freight and delivery prepaid to the seller, which shall be the buyer's sole remedy for defective materials. Seller shall not be liable to purchaser or any other person for consequential or incidental damages. Hydraulic and electrical components are subject to their respective manufacturer's warranties. This warranty does not apply to machines and / or components, which have been altered in any way, or subjected to abusive or abnormal use, inadequate maintenance, and lubrication, or to use beyond seller’s recommended capacities and specifications. Seller shall not be liable under any circumstances for labor costs expended on such goods or consequential damages. Seller shall not be liable to purchaser or any other person for loss or damage directly or indirectly arising from the use of the goods, or from any other cause. No employee, agent, officer, or seller is authorized to make oral representations or warranty of fitness or to waive any of the foregoing terms of sale and none shall be binding on the seller. 4 INTRODUCTION The Piranha Ironworker is a compact hydraulically powered machine that shears, punches, bends, notches, and copes, all in a low silhouette, efficiently designed unit, resulting in minimal floor space requirements. The integral lifting point provides instant portability and the unit arrives fully assembled, requiring only the addition of hydraulic oil and electrical power to become fully operational. The platen has six 5/8-11 tapped holes giving a wide base for increased flexibility of attachment sizes. The shearing operation features an adjustable manual hold-down allowing the operator to clamp the work piece with a slight initial adjustment. All workstations are located approximately 42" off the floor for ease of operation. The first part of this manual provides operations and maintenance instructions, including a section on troubleshooting various problems that may occur. The second part of this manual provides repair parts information and a complete parts list with their respective part numbers. Proper understanding and application of the information and procedures given in this manual will aid in establishing a preventative maintenance program and, provide assistance for correcting malfunctions that may occur in the machine. The repair parts list provides information for parts procurement as well as assembly breakdowns to aid in disassembly and re-assembly for repair part installation. 5 SAFETY PRECAUTIONS The operator of this machine should view the operational video provided with the machine, and thoroughly understand this manual before starting any operation. This machine was designed for use by a single operator only. Wear eye protection at all times. Use the proper voltage outlet for your machine. Make sure that all guards and cover shields are down before starting machine. CAUTION: Do not remove guards. Keep hands off working tables and out of the path of moving parts during operation. Remove all material from the tables except for the work piece. Remove all tooling from the punch end before starting shearing or coping operations. Make sure that all tooling is properly held in position before starting any operation. The area around the machine should be well lighted, dry, and as free from obstructions as possible. All maintenance and repair work should be performed by a person familiar with this publication. At the end of the working day, the operator should turn the power off to the machine. Adjust limit switches when punching or bending to allow 1/4" maximum clearance between bottom of the stripper foot or bending punch and the top of the material. Contact the factory for limit switch adjustments on special tooling. Turn the machine "OFF" when changing tooling or performing maintenance work. 6 MACHINE SPECIFICATIONS HYDRAULIC SYSTEM Drive Motor 3HP 230 / 460 Volt / 3 Phase Hydraulic Tank Capacity 12 Gallons Hydraulic Oil Mobile DTE 13M or Equivalent (ISO Grade 32) Consult your local distributor for a cross reference WORKING SURFACE Platen Table 8" x 16" Coper Table 12" x 14" CAPACITIES Punch Maximum 13/16" Thru 3/4" thick material or 50 Tons Bending Maximum 50 Tons Punch End Maximum 50 Tons Bar 1-1/2" Round or 1" Square Plate 3/4" x 6", 1/2" x 10", or 1/4” x 13” Angle 3" x 3" x 3/8" Coper-Notcher 2-1/4" x 3" x 1/4" WEIGHT Shipping Weight 1,700 Pounds 7 Rear Stop Box (OFF SIDE) FUNCTIONAL DIAGRAM Hold-down Lifting Hole Stroke Control Angle Table Shear Table Coper Guard Punch Attachment COPER END PUNCH END Coper Table Platen Table Front Control Box Serial Number Plate Location 8 DIMENSIONAL DATA 9 Standards Compliance Electrical System Design/Manufacture: The machines manufactured in Rockford, Illinois, USA are furnished with electrical
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